SIMATIC. ET 200AL Distributed I/O system. Preface. ET 200AL Documentation Guide 1. System overview 2. Application planning 3. Mounting 4.

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Distributed I/O system

SIMATIC ET 200AL

Distributed I/O system

System Manual

Preface

ET 200AL Documentation

Guide 1

System overview 2

Application planning 3

Mounting 4

Connecting 5

Configuring 6

Configuration control

(option handling) 7

Commissioning 8

Maintenance 9

Technical specifications 10

Safety-related shutdown of

ET200AL standard modules A

Dimension drawings B

Accessories/spare parts C

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Siemens AG Digital Industries Postfach 48 48 90026 NÜRNBERG GERMANY

A5E31861578-AJ

Legal information

Warning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.

DANGER

indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING

indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION

indicates that minor personal injury can result if proper precautions are not taken.

NOTICE

indicates that property damage can result if proper precautions are not taken.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified Personnel

The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions.

Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Proper use of Siemens products Note the following:

WARNING

Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks

All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

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Preface

Purpose of the documentation

This documentation provides you with important information on how to configure, install, wire and commission the SIMATIC ET 200AL distributed I/O system.

Changes compared to previous version

This manual contains the following changes compared to the previous version:

• Update of the section Safety-related shutdown of ET200AL standard modules (Page 110)

• Additions to the fail-safe I/O module

Basic knowledge required

A basic knowledge of automation technology is required to understand the documentation.

Validity of the documentation

This documentation is valid for the SIMATIC ET 200AL distributed I/O system.

Conventions

Please observe notes labeled as follows:

Note

A note contains important information on the product described in the documentation and on the handling of the product to which particular attention should be paid.

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4 System Manual, 08/2021, A5E31861578-AJ

Special information

Note

Important note for maintaining operational safety of your plant

Plants with safety-related features are subject to special operational safety requirements on the part of the operator. The supplier is also obliged to comply with special product

monitoring measures. For this reason, we inform you in personal notifications about product developments and features that are (or could be) relevant to the operation of systems from a safety perspective.

You should subscribe to the corresponding notifications in order to obtain the latest information and to allow you to make any necessary modifications to your system.

Log on to Industry Online Support. Follow the links below and click on "Email on update" on the right-hand side in each case:

• SIMATIC S7-300/S7-300F (https://support.industry.siemens.com/cs/ww/en/ps/13751)

• SIMATIC S7-400/S7-400H/S7-400F/FH

(https://support.industry.siemens.com/cs/ww/en/ps/13828)

• SIMATIC WinAC RTX (F) (https://support.industry.siemens.com/cs/ww/en/ps/13915)

• SIMATIC S7-1500/SIMATIC S7-1500F

• SIMATIC S7-1200/SIMATIC S7-1200F

• Distributed I/O (https://support.industry.siemens.com/cs/ww/en/ps/14029)

• STEP 7 (TIA Portal) (https://support.industry.siemens.com/cs/ww/en/ps/14667) Note

When using F-CPUs in safety mode and fail-safe modules, observe the description of the SIMATIC Industrial Software SIMATIC Safety - Configuring and Programming

(https://support.industry.siemens.com/cs/ww/de/view/54110126/en) fail-safe system.

Recycling and disposal

For ecologically sustainable recycling and disposal of your old device, contact a certificated disposal service for electronic scrap and dispose of the device in accordance with the regulations in your country.

Additional support

• Information about Technical Support is available in section Siemens Industry Online Support (Page 5).

• The range of technical documentation for the individual SIMATIC products and systems can be found on the Internet (https://www.siemens.com/simatic-tech-doku-portal).

• Information about the online catalog and online order system is available in section Industry Mall (Page 6).

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Security information

Siemens provides products and solutions with industrial security functions that support the secure operation of plants, systems, machines and networks.

In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial security concept. Siemens’ products and solutions constitute one element of such a concept.

Customers are responsible for preventing unauthorized access to their plants, systems, machines and networks. Such systems, machines and components should only be connected to an enterprise network or the internet if and to the extent such a connection is necessary and only when appropriate security measures (e.g. firewalls and/or network segmentation) are in place.

For additional information on industrial security measures that may be implemented, please visit (https://www.siemens.com/industrialsecurity).

Siemens' products and solutions undergo continuous development to make them more secure. Siemens strongly recommends that product updates are applied as soon as they are available and that the latest product versions are used. Use of product versions that are no longer supported, and failure to apply the latest updates may increase customers' exposure to cyber threats.

To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed visit (https://www.siemens.com/industrialsecurity).

Siemens Industry Online Support

You can find current information on the following topics quickly and easily here:

• Product support

All the information and extensive know-how on your product, technical specifications, FAQs, certificates, downloads, and manuals.

• Application examples

Tools and examples to solve your automation tasks – as well as function blocks, performance information and videos.

• Services

Information about Industry Services, Field Services, Technical Support, spare parts and training offers.

• Forums

For answers and solutions concerning automation technology.

• mySupport

Your personal working area in Industry Online Support for messages, support queries, and configurable documents.

This information is provided by the Siemens Industry Online Support in the Internet (https://www.siemens.com/automation/service&support).

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Industry Mall

The Industry Mall is the catalog and order system of Siemens AG for automation and drive solutions on the basis of Totally Integrated Automation (TIA) and Totally Integrated Power (TIP).

You can find catalogs for all automation and drive products on the Internet.

ET 200AL Documentation Guide 1

The documentation for the SIMATIC ET 200AL distributed I/O system is arranged into three areas.

This arrangement enables you to access the specific content you require.

Basic information

The System Manual and Getting Started describe in detail the configuration, installation, wiring and commissioning of the SIMATIC ET 200AL distributed I/O system. The STEP 7 online help supports you in the configuration and programming.

Device information

Product manuals contain a compact description of the module-specific information, such as properties, wiring diagrams, characteristics and technical specifications.

General information

The function manuals contain detailed descriptions on general topics regarding the SIMATIC ET 200AL distributed I/O system, e.g. diagnostics, communication, Motion Control, Web server.

You can download the documentation free of charge from the Internet (https://support.industry.siemens.com/cs/ww/en/view/109742667).

Manual Collection ET 200AL

The Manual Collection contains the complete documentation on the SIMATIC ET 200AL distributed I/O system gathered together in one file.

You can find the Manual Collection on the Internet

(https://support.automation.siemens.com/WW/view/en/95242965).

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"mySupport"

With "mySupport", your personal workspace, you make the best out of your Industry Online Support.

In "mySupport", you can save filters, favorites and tags, request CAx data and compile your personal library in the Documentation area. In addition, your data is already filled out in support requests and you can get an overview of your current requests at any time.

You must register once to use the full functionality of "mySupport".

You can find "mySupport" on the Internet (https://support.industry.siemens.com/My/ww/en).

"mySupport" - Documentation

With "mySupport", your personal workspace, you make the best out of your Industry Online Support.

In "mySupport", you can save filters, favorites and tags, request CAx data and compile your personal library in the Documentation area. In addition, your data is already filled out in support requests and you can get an overview of your current requests at any time.

You must register once to use the full functionality of "mySupport".

You can find "mySupport" on the Internet

(https://support.industry.siemens.com/My/ww/en/documentation).

"mySupport" - CAx data

In the CAx data area of "mySupport", you can access the latest product data for your CAx or CAe system.

You configure your own download package with a few clicks.

In doing so you can select:

• Product images, 2D dimension drawings, 3D models, internal circuit diagrams, EPLAN macro files

• Manuals, characteristics, operating manuals, certificates

• Product master data

You can find "mySupport" - CAx data on the Internet

(https://support.industry.siemens.com/my/ww/en/CAxOnline).

Application examples

The application examples support you with various tools and examples for solving your automation tasks. Solutions are shown in interplay with multiple components in the system - separated from the focus on individual products.

You will find the application examples on the Internet (https://support.industry.siemens.com/cs/ww/en/ps/ae).

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TIA Selection Tool

With the TIA Selection Tool, you can select, configure and order devices for Totally Integrated Automation (TIA).

This tool is the successor of the SIMATIC Selection Tool and combines the known configurators for automation technology into one tool.

With the TIA Selection Tool, you can generate a complete order list from your product selection or product configuration.

You can find the TIA Selection Tool on the Internet

(https://support.industry.siemens.com/cs/ww/en/view/109767888).

SIMATIC Automation Tool

You can use the SIMATIC Automation Tool to perform commissioning and maintenance activities simultaneously on various SIMATIC S7 stations as a bulk operation independent of TIA Portal.

The SIMATIC Automation Tool provides a multitude of functions:

• Scanning of a PROFINET/Ethernet system network and identification of all connected CPUs

• Address assignment (IP, subnet, gateway) and station name (PROFINET device) to a CPU

• Transfer of the date and the programming device/PC time converted to UTC time to the module

• Program download to CPU

• RUN/STOP mode switchover

• CPU localization by means of LED flashing

• Reading out of CPU error information

• Reading of the CPU diagnostics buffer

• Reset to factory settings

• Firmware update of the CPU and connected modules You can find the SIMATIC Automation Tool on the Internet

PRONETA

SIEMENS PRONETA (PROFINET network analysis) allows you to analyze the plant network during commissioning. PRONETA features two core functions:

• The topology overview automatically scans the PROFINET and all connected components.

• The IO check is a fast test of the wiring and the module configuration of a plant.

You can find SIEMENS PRONETA on the Internet

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SINETPLAN

SINETPLAN, the Siemens Network Planner, supports you in planning automation systems and networks based on PROFINET. The tool facilitates professional and predictive dimensioning of your PROFINET installation as early as in the planning stage. In addition, SINETPLAN supports you during network optimization and helps you to exploit network resources optimally and to plan reserves. This helps to prevent problems in commissioning or failures during productive operation even in advance of a planned operation. This increases the availability of the production plant and helps improve operational safety.

The advantages at a glance

• Network optimization thanks to port-specific calculation of the network load

• Increased production availability thanks to online scan and verification of existing systems

• Transparency before commissioning through importing and simulation of existing STEP 7 projects

• Efficiency through securing existing investments in the long term and the optimal use of resources

You can find SINETPLAN on the Internet (https://www.siemens.com/sinetplan).

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System overview 2

2.1 What is the SIMATIC ET 200AL distributed I/O system?

SIMATIC ET 200AL

The SIMATIC ET 200AL distributed I/O system is a scalable and highly flexible, distributed I/O system for connecting process signals to a higher-level control system with a field bus.

Customer benefits of the system

Figure 2-1 ET 200AL benefits

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2.1 What is the SIMATIC ET 200AL distributed I/O system?

Area of application

The SIMATIC ET 200AL distributed I/O system is especially well suited for use in tight spaces, moving applications and for assembly and handling technology. Thanks to its scalable construction, you have the option to precisely customize its configuration to your on site needs.

The SIMATIC ET 200AL distributed I/O system features degree of protection IP65/IP67. The I/O modules are suitable for distributed use indoors on a machine or assembly line.

Setup

The SIMATIC ET 200AL distributed I/O system is made up of the following components:

• Interface modules (PROFINET/PROFIBUS)

• Digital and analog I/O modules

• Communication module

After an interface module you can configure 2 lines (ET-Connection), each with 16 modules.

Alternatively, you can configure a line with 16 I/O modules on the SIMATIC ET 200SP distributed I/O system with BaseUnit BU-Send and the BusAdapter BA-Send 1xFC.

The ET-Connection backplane bus is designed as a cable. This allows you to create spatial distances of up to 15 m between the modules.

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2.1 What is the SIMATIC ET 200AL distributed I/O system?

Configuration example

The figure below shows a configuration example of the SIMATIC ET 200AL distributed I/O system with a PROFINET interface module.

① Interface module (PROFINET)

② Fail-safe digital input / digital output module

③ Digital input/Digital output module

④ Digital output module

⑤ Analog input module

⑥ Communication module

⑦ PROFINET cable

⑧ Power supply cable

⑨ ET-Connection cable

⑩ Sealing caps

Figure 2-2 Configuration example of the ET 200AL

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2.2 What are fail-safe automation systems and fail-safe modules?

2.2 What are fail-safe automation systems and fail-safe modules?

Fail-safe automation systems

Fail-safe automation systems are mainly used in applications where failure could have consequences for the safety of people and/or the environment. Fail-safe systems are therefore intended to reduce hazards or failures that could cause physical damage. Their purpose is to ensure a tolerable level of risk.

F-systems are used to control processes and provide a safe operating state when faults are detected. Fault detection is ensured by a very high level of diagnostic coverage. When a fault is detected, appropriate actions are initiated to bring the affected application to a safe state.

F-systems offer improved fault detection and fault localization through detailed diagnostics and diagnostic messages. This is the most important difference between fail-safe systems and standard systems. The use of fail-safe systems should be considered for applications where hazards are inherent and can cause physical damage.

Safety Integrated

Safety Integrated is the integrated safety concept for automation and drive technology from Siemens.

Proven technologies and systems from automation technology are used for safety systems.

Safety Integrated includes the complete safety sequence, ranging from sensor, actuator and fail-safe modules right through to the controller, including safety-related communication via standard fieldbuses. Drives and controllers handle safety tasks in addition to their actual functions.

Fail-safe modules

The key difference between fail-safe modules (F-modules) and standard modules is that they have an internal two-channel design. This means the two integrated processors monitor each other, automatically test the input and output circuits, and switch the fail-safe module to a safe state in the event of a fault.

The F-CPU communicates with a fail-safe module via the safety-related PROFIsafe bus profile.

Possible uses of ET 200AL with fail-safe modules

The use of ET 200AL with fail-safe modules makes it possible to replace conventional mounting technology in safety technology with PLC components. This also includes the replacement of switchgear for EMERGENCY STOP, safety door monitoring, ambidextrous operation, etc.

Fail-safe modules for ET 200AL are supported together with the STEP 7 Safety Advanced V17 or higher option package.

F-modules for ET 200AL can be used either with an ET 200AL PROFINET interface module (IM), a direct ET connection to an ET 200SP F-CPU or a direct ET connection to an ET 200SP IM (mixed configuration).

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2.2 What are fail-safe automation systems and fail-safe modules?

Use in SIMATIC Safety F-systems

The fail-safe ET 200AL modules can be used with STEP 7 Safety Advanced from V17 with PROFINET and direct ET connection configurations together with an F-CPU.

The fail-safe modules can only be used in safety mode. Fault safe and non-fault safe modules can be combined within one ET 200AL ET connection.

Achievable safety classes

The fail-safe modules are equipped with integrated safety functions for safety mode.

You can achieve the safety classes of the table below:

• With the appropriate parameter assignment of the safety functions in STEP 7

• With a specific combination of fail-safe and non-fail-safe I/O modules

• With a special arrangement and wiring of the sensors and actuators

Table 2- 1 Safety classes that can be achieved with ET 200AL in safety mode Safety class in safety mode

According to IEC 61508 According to ISO 13849-1

SIL2 Category 3 (PL) Performance Level d

SIL3 Category 3 (PL) Performance Level e

SIL3 Category 4 (PL) Performance Level e

WARNING

The safety performance of your installation depends on the design and ongoing maintenance of the individual complete safety function.

SIMATIC fail-safe CPUs and ET 200AL fail-safe modules have logic processing components with certified safety integrity levels, provided they are operated in accordance with classifications, specifications, and instructions.

Failure to adhere to this may cause damage or unpredictable operation, resulting in fatal or serious injury and/or property damage.

To achieve the level of safety you require, you need to select all components of your plant and construct and maintain them in accordance with accepted safety standards and practices.

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2.3 Components

2.3 Components

Components of the ET 200AL distributed I/O system

The following table shows and explains the function of the most important components of the ET 200AL distributed I/O system.

Table 2- 2 Components of the ET 200AL distributed I/O system

Components Function View

Interface module for PROFINET IO • The interface module connects the ET 200AL distributed I/O system with the IO controller

• Exchanges data with the I/O modules via ET-Connection

Interface module for PROFIBUS DP • The interface module connects the ET 200AL distributed I/O system with the DP master

• Exchanges data with the I/O modules via ET-Connection

I/O modules • The I/O modules form the interface to the process

• Recording and controlling the current process status via the connected sensors and actuators

eCoding plug connector Electronic coding element with an overwrita- ble electronic memory for module-specific fail- safe address data (for example, the F-

destination address)

Y-cable Y-cable connects multiple actuators or sensors to inputs or outputs. There are two types:

• Y-cable: Connects inputs or outputs of the module to several actuators or sensors.

• Inverted Y-cable: Connects several fail-safe inputs or outputs of the F-module with one or more sensors and actuators

Identification labels • The identification labels come with the module and can be machine printed

• Can be ordered separately in white or yel- low for fail-safe modules

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2.3 Components

Components Function View

Bus cable and M8 connector for

ET-Connection The bus cable creates the bus connection between the modules

Power cable and M8 connector for

power supply The power cable provides power to the modules

Stripping tool ET-Connection The stripping tool is used to strip the ET- Connection bus cable

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Application planning 3

3.1 Hardware configuration

Mechanical maximum configuration

The following tables show the rules of the mechanical configuration. As soon as one of the following rules applies, the maximum configuration has been reached.

Table 3- 1 Maximum mechanical configuration - on ET 200AL interface module

Properties Rule (max.)

Interface modules as of firmware ver-

sion V1.0.0

sion V1.0.1 Number of ET 200AL I/O modules in the configuration 32

Number of ET-Connection outlets 2

Number of I/O modules per ET-Connection outlet 16

Spatial extension per ET-Connection line 160 m 240 m

Cable length between the modules 10 m 15 m

Table 3- 2 Maximum mechanical configuration - on ET 200SP with interface module

sion V3.0.0

sion V3.3.0 Number of ET 200AL I/O modules in the configuration 16

Spatial extension ET-Connection line 160 m 240 m

Cable length between the modules 10 m 15 m

Table 3- 3 Maximum mechanical configuration - on ET 200SP with CPU

CPUs with firmware version as of V2.0.0 Number of ET 200AL I/O modules in the configuration 16

Spatial extension ET-Connection line 240 m

Cable length between the modules 15 m

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3.2 Configuration variants with ET-Connection

Electrical maximum configuration

The number of usable I/O modules of a potential group is limited by the following points:

• Power requirements of the I/O modules

• Power requirements of the components supplied via these I/O modules

The maximum infeed current of the I/O modules is 4 A with 1L+ supply voltage (non- switched) and 2L+ load voltage (switched). When the maximum infeed current has been reached, you must open a new potential group.

Reference

You will find more information in the section Connecting cables for ET 200AL (Page 50).

3.2 Configuration variants with ET-Connection

3.2.1 ET 200AL with ET-Connection

Every ET 200AL interface module has 2 ET-Connection connections

From every ET-Connection, you have the option to set up a line with a maximum of 16 ET 200AL I/O modules.

ET-Connection1

The figure below shows a configuration in the IP65/IP67 environment with one ET-Connection line.

Figure 3-1 ET 200AL with ET-Connection1

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ET-Connection1 and ET-Connection2

The figure below shows a configuration in the IP65/IP67 environment with two ET- Connection lines

Figure 3-2 ET 200AL with ET-Connection1 and ET-Connection2

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3.2.2 Hybrid configuration ET 200AL/ET 200SP with ET-Connection

Hybrid configuration ET 200AL and ET 200SP

You have the possibility to integrate standard and fail-safe I/O modules of the distributed I/O systems ET 200AL (IP65/IP67) into a configuration of the distributed I/O system ET 200SP (IP20). Fail-safe and non-fail-safe modules may be combined at will in the ET 200AL

distributed I/O system.

The figure below shows a combination of the modules of the ET 200AL and ET 200SP distributed I/O systems.

Figure 3-3 Hybrid configuration ET 200SP and ET 200AL with ET-Connection

Requirement

For a hybrid configuration, you need at least the following components:

• Interface module or CPU Note

Use of a F-CPU with F-modules

A fail-safe CPU must also be used when using a fail-safe module in the ET 200AL.

• BaseUnit BU-Send with BusAdapter BA-Send 1xFC

• ET-Connection cable pre-assembled on one side

• Power cable pre-assembled on one side

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Rules

When putting together a hybrid configuration, you must observe the following rules:

• The bus length of the ET 200SP distributed I/O system is a maximum of 1 m

(excluding interface module/CPU, including BU-Send, BA-Send 1×FC and server module).

• A maximum of 16 ET 200AL I/O modules can be connected to ET-Connection.

• The maximum length of the bus cable for ET-Connection between two modules is 15 m.

Rules

The following table shows a rough overview of the functions of the ET 200AL I/O modules in combination with the ET 200SP.

Function Hybrid configuration

ET 200SP ET 200AL I/O modules on ET connection

IM CPU

Isochronous mode ● -- --

Configuration control ● ● ●

Shared device ● ● ●

PROFIenergy ●¹ -- ●¹

System redundancy S2 ●² -- ●²

1) PROFIenergy is not supported by fail-safe I/O module F-DI 4+F-DQ 2x24VDC/2A, 4xM12

2) With IM 155-6 PN/3 HF and IM 155-6 PN/2 HF as of V4.2 Details on the hybrid configuration are available here

(https://support.industry.siemens.com/cs/de/en/view/100300517).

Procedure

Watch video sequence (https://support.industry.siemens.com/cs/ww/en/view/95886672) Proceed as follows to put together a multi-tier configuration:

1. Mount the BaseUnit BU-Send directly to the right of the ET 200SP interface module or the ET 200SP CPU.

2. Then install the other BaseUnits/I/O modules for the ET 200SP distributed I/O system and the server module.

3. Connect the bus cable for ET-Connection to the BusAdapter BA-Send 1×FC and install it on the BaseUnit BU-Send.

4. Fasten the BusAdapter BA-Send 1×FC with the BaseUnit BU-Send (1 screw with tightening torque of 0.2 Nm). Use a screwdriver with a 3 to 3.5 mm blade to do this.

5. Connect the other end of the bus cable for ET-Connection (with M8 plug) to the first ET 200AL I/O module (socket X30 ET-Connection IN).

6. Connect the supply voltage (24 V DC) to the ET 200AL I/O modules (X80 plug).

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Mounting 4

4.1 Basics

Introduction

All the modules of the ET 200AL distributed I/O system are designed for the degree of protection IP65/IP67. This means that you can directly mount this system in your plant.

Installation position

You can mount the ET 200AL distributed I/O system in any position.

Minimum clearances

At ambient temperatures of 50 °C or higher, please ensure that the module is mounted at a distance of least 1 cm from an adjacent module or another device.

Mounting rules

When mounting the modules, you do not need to following any special rules.

Note

Mounting of the modules

Mount the ET 200AL distributed I/O system only with disconnected supply voltages.

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4.2 Mounting modules

4.2 Mounting modules

Introduction

The modules of the ET 200AL distributed I/O system are designed for installation on a level, firm surface.

Thanks to the axisymmetrical drill holes in the modules, you have the option to fasten the modules on an aluminum profile using tee nuts.

The following images shows the aluminum profile on which you can mount the modules.

Figure 4-1 Aluminum profile

Required tools

For installation, you need a screwdriver or an Allen wrench.

Required screws

The following table shows and explains the screw types required to mount the modules.

Table 4- 1 Recommended screws

Screw type Explanation

Socket head cap screw M4 according to DIN EN

ISO 1207 / DIN EN ISO 1580 The screw length must be at least 30 mm.

If you need washers, use DIN EN ISO 7089/DIN EN ISO 7090 washers.

Hexagon socket head cap screw M4 according to DIN EN ISO 4762

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Drill holes of the modules

All modules of the ET 200AL distributed I/O system feature a uniform drill pattern.

• All module housings are axisymmetrical.

• The distance between the top and bottom drill hole is identical for all modules.

Mounting interface module and 45 mm I/O modules (front)

Watch video sequence (https://support.industry.siemens.com/cs/ww/en/view/95886672) The interface modules and the 45 mm I/O modules have an attachment point on top and on the bottom.

To mount an interface module or 45 mm I/O module, follow these steps:

1. Drill 2 fastening holes with 4.5 mm diameter at a distance of 149.6 mm.

2. Fasten the interface module or the 45 mm I/O module with the screws to both fastening points (tightening torque 1.2 Nm).

The figure below shows the dimensions for fastening the IM 157-1 PN interface module and the DQ 8x24VDC/2A 8xM12 45 mm I/O module.

Figure 4-2 Dimensions for mounting interface modules and 45 mm I/O modules

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Mounting 30 mm I/O modules (front or side)

Watch video sequence (https://support.industry.siemens.com/cs/ww/en/view/95886672) The 30 mm I/O modules have an attachment point on top and on the bottom. You also have the option of fastening the 30 mm I/O modules at the side. When fastening them at the side, you must use the supplied spacers.

To mount a 30 mm I/O module, follow these steps:

1. Drill 2 fastening holes with 4.5 mm diameter at a distance of 149.6 mm.

2. Use the supplied spacers for side fastening of the I/O module on the top and bottom (on one side adjacent to the fastening surface).

3. Fasten the I/O module with the screws to both fastening points (tightening torque 1.2 Nm).

The figure below shows the dimensions for fastening the 30 mm I/O modules using the example of the DIQ 4+DQ 4x24VDC/0.5A 8xM8 I/O module.

Figure 4-3 Dimensions for mounting 30 mm I/O modules

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Fastening for cable ties

All module of the ET 200AL distributed I/O system have an integrated attachment point for cable ties. The attachment points are found on all four corners of the modules.

The figure below shows the top left attachment point for 2.5 mm wide cable ties for fastening the cables.

Figure 4-4 Top left attachment point for cable ties

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Connecting 5

5.1 Rules and regulations for operation

Introduction

Depending on the area of application, the ET 200AL distributed I/O system, as a component of plants and systems, requires that special rules and specifications be followed.

This section gives an overview of the most important rules to be followed for integration of the ET 200AL distributed I/O system in a plant or in a system.

Specific application

Follow the safety and accident prevention regulations applicable to specific applications, e.g. the machinery directive.

EMERGENCY-STOP device

EMERGENCY-STOP devices according to IEC 60204 (corresponds to DIN VDE 113) must remain in effect in all operating modes of the plant or system.

Excluding hazardous system conditions

Hazardous plant states must not occur.

Ensure that dangerous system conditions are excluded, even in the following situations:

• In the event of a voltage dip or power outage

• When the plant restarts after a voltage dip or power outage

• When the ET 200AL distributed I/O system restarts after interruption of PROFINET communication

If necessary, force the EMERGENCY OFF.

An uncontrolled or undefined startup is not permitted after the "EMERGENCY STOP" is unlocked.

Cables and wires

Make sure that the cables used (incl. connectors) are approved for a continuous operating temperature of at least 70 °C.

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5.1 Rules and regulations for operation

External fuses/switches

External fuses and switches must be installed so that they meet the standards for cable and device protection applicable to your application.

Line voltage of the SELV/PELV power supply

The following section describes what you need to pay attention to with respect to the line voltage (you will find additional information in the section Information on insulation, protection class, degree of protection, and rated voltage (Page 108)):

• For stationary plants or systems without an all-pole line disconnector, there must be a disconnector unit (all-pole) fitted in the building installation.

• For load current supplies, the configured rated voltage range must correspond to the local line voltage.

• For all power circuits of the ET 200AL distributed I/O system, the fluctuation/deviation of the line voltage from the rated value must be within the permitted tolerance.

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24 V DC supply

Below there is a description of what you need to pay attention to with 24 V DC supply:

• For buildings:

If there is a danger due to overvoltages, you must take lightning protection measures for external lightning protection (e.g. lighting protection elements).

• With 24 V DC supply lines and signal lines:

If there is a danger due to overvoltages, you must take lightning protection measures for internal lightning protection (e.g. lightning protection elements. You will find additional information in the Designing interference-free controllers

(https://support.industry.siemens.com/cs/ww/en/view/59193566) function manual).

• For 24 V DC supply:

Ensure that there is a safe (electrical) separation of low voltage (SELV/PELV) according to IEC 61010-2-201 or IEC 60950-1.

You must secure all feeding supply voltages with a UL/IEC approved fuse 24 V DC/4 A (trigger characteristic type B or C).

• Continuous operation of fail-safe modules with more than 28.8 V DC can result in personal injury and equipment damage.

WARNING

Continuous operation of fail-safe modules with more than 28.8 V DC can result in personal injury and equipment damage.

Certain transients from certain source impedances (for example according to EN 61000-4-2, 61000- 4 4 and 61000-4- 5), as specified in the "Electromagnetic compatibility" section, can act on this voltage without interrupting operation or causing damage.

Operate the fail-safe module within the voltage parameters specified in the technical specifications. This will avoid unacceptable temperature increases and heat damage that will cause the module to lose its functionality.

Requirements for power supplies in the event of a power interruption

To ensure compliance with IEC 61131-2, use only power supply units/power supplies with a power failure bridging time of at least 20 ms. Observe the relevant requirement in your product standards (e.g. 30 ms for "burners" according to EN 298) with regard to possible voltage interruptions. You can find the latest information on power supply components on the Internet.

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Protection against outside electrical influences

Below is a description of what you must pay attention to in terms of protection against electrical impacts and/or faults:

• For all plants or systems in which the ET 200AL distributed I/O system is integrated, you must ensure that the equipment or system is functionally grounded to discharge electromagnetic interference.

• For supply, signal and bus cables, you must ensure that the cable routing and installation is correct.

• For signal and bus cables, you must ensure that a wire/cable breakage or a cross-wire does not lead to undefined states of the plant or system.

Reference

Additional information can be found in the function manual Designing interference-free controllers (https://support.industry.siemens.com/cs/ww/en/view/59193566).

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5.2 Additional rules and regulations for the operation of the ET 200AL with fail-safe modules

5.2 Additional rules and regulations for the operation of the ET 200AL with fail-safe modules

5.2.1 Safety extra-low-voltage (SELV, PELV) for fail-safe modules

WARNING

The fail-safe modules must be operated with a safe extra-low voltage (SELV, PELV).

You can find additional information on safety extra-low voltage (SELV, PELV) in the data sheets of the applicable power supplies, for example.

The fail-safe modules operate at a rated voltage of 24 V DC. The tolerance range is 20.4 V DC to 28.8 V DC.

Within the overvoltage range from 28.8 V DC to 35 V DC, the F-modules react in a fail-safe manner and the inputs and outputs are passivated. For overvoltages higher than 35 V DC, the F-modules are permanently de-energized.

Use a power supply unit that does not exceed U^m = 35 V DC even in the event of a fault. For more on this, refer to the information in the data sheet on overvoltage protection in the case of an internal error. Or implement appropriate measures to limit the voltage, e.g. use of an overvoltage protector.

All system components that can supply electrical energy in any form whatsoever must fulfill this condition.

Each additional circuit (24 V DC) used in the system must have a safety extra-low voltage (SELV, PELV). Refer to the relevant data sheets or contact the manufacturer.

Sensors and actuators with an external power supply can also be connected to F-modules.

Make sure that power is supplied to these components from safety extra-low voltage (SELV, PELV) as well. The process signal of a 24 V DC digital module must not exceed a fault voltage U^m in the event of a fault.

WARNING

Even when a fault occurs, the permissible potential difference between the supply of the interface module (bus voltage) and the load voltage must not be exceeded.

An external direct electrical connection is one way to meet this requirement. This also prevents potential differences from causing voltage additions at the individual voltage sources, which would cause the fault voltage U^m to be exceeded.

Immunity to surge voltages

To meet the product standard for burner controls (EN 298), the wiring must be equipped with external protection against coupled surge voltages caused by lightning. Further information on this can be found in the function manual Designing interference-free controllers (https://support.industry.siemens.com/cs/ww/en/view/59193566).

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5.2.2 Requirements for sensors and actuators for fail-safe modules

General requirements for sensors and actuators

Note the following important warning regarding safety-related use of sensors and actuators:

WARNING

Note that instrumentation with sensors and actuators bears a considerable safety responsibility. Also bear in mind that sensors and actuators generally do not have proof- test intervals of 20 years as defined in IEC 61508:2010 without considerable loss of safety.

The probability of hazardous faults and the rate of hazardous faults of safety functions must comply with an SIL-defined high limit. A listing of values achieved by F-modules in the technical specifications of the F-modules is available under "Fail-safe performance characteristics".

To achieve the required safety class, suitably qualified sensors and actuators are necessary.

Additional sensor requirements

General rule: To achieve SIL3/Cat. 3/PLe, a single-channel sensor is adequate. However, to achieve SIL3/Cat. 3/PLe with a single-channel sensor, the sensor itself must be SIL3/Cat. 3/PLe- capable; otherwise the sensor must be connected by two channels to achieve this safety level.

To achieve SIL3/Cat. 4/PLe, sensors must be connected by two channels.

WARNING

In the case of fail-safe input modules, the value "0" is output to the F-CPU after detection of faults. You therefore need to make sure that the sensors are implemented in such a way as to ensure the reliable reaction of the safety program when the sensor is in the "0" state.

Example: In its safety program, an EMERGENCY-STOP sensor must achieve the shutdown of the relevant actuator when it is in the "0" state (EMERGENCY-STOP button pressed).

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Duration requirements for sensor signals

WARNING

Observe the following requirements for sensor signals:

• To ensure the correct detection of the sensor signals via fail-safe modules with inputs, you need to make sure that the sensor signals are output for a minimum duration.

• For pulses to be detected with certainty, the time between two signal changes (pulse duration) must be greater than the PROFIsafe monitoring time.

Reliable detection by F-modules with inputs

The minimum duration of sensor signals for F-modules with inputs depends on the

configured input delay, the parameters of the short circuit test of the sensor supplies, and the configured discrepancy behavior for 1oo2 evaluation. The signal must be greater than the maximum response time of the configured application. Information on calculating the maximum response time can be found in the section "Response times" of the relevant F- module.

The maximum permitted switching frequency of the sensor signals results from the minimum duration.

Additional requirements for actuators

The fail-safe output modules test the outputs at regular intervals. The F-module briefly switches off the activated outputs and, if necessary, switches on the deactivated outputs. You can assign the maximum duration of the test pulses (dark and light period) with parameters.

Fast reacting actuators may briefly drop out or be activated during the test. If your process does not tolerate this, set the pulse duration of the light or dark test correspondingly or use actuators that have sufficient lag.

WARNING

If the actuators switch voltages greater than 24 V DC (e.g. 230 V AC), the outputs of a fail- safe output module and the parts carrying a higher voltage must be electrically isolated (in accordance with IEC 60664-1).

This is generally the case for relays and contactors. Particular attention must be paid to this with semiconductor switching devices.

Technical specifications of sensors and actuators

Refer to the manuals of the fail-safe modules for technical specifications to assist you in selecting sensors and actuators.

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5.2.3 Crosstalk of digital input/output signals

Readback errors may occur on the F-DQ channels if the fail-safe digital output signals and fail- safe digital input signals are routed through a single cable.

Cause: capacitive crosstalk

During the bit pattern test of the outputs or the sensor supply of the inputs, the steep switching edge of the output drivers caused by the coupling capacitance of the line may result in crosstalk to other non-activated output or input channels. This may then lead to a response of the readback circuit in these channels. A cross circuit/short-circuit is detected, which leads to safety-related tripping.

Remedy:

• Separate cables for fail-safe DQ modules and non-fail-safe DQ modules

• Separate cables for F-DQ channel and F-DI channels

• Coupling relay or diodes in the outputs

• Disable the sensor supply test if safety class requirements allow it.

Cause: magnetic crosstalk

Note that an inductive load connected to the F-DQ channels can induce coupling of a strong magnetic field.

Remedy:

• Separate the inductive loads spatially or shield against the magnetic field.

• Configure the readback time to 50 ms or higher.

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5.3 Operation of the ET 200AL on grounded/non-grounded infeed

5.3 Operation of the ET 200AL on grounded/non-grounded infeed

Introduction

Information is provided below on the overall configuration of an ET 200AL distributed I/O system on a grounded incoming supply (TN-S network). The specific subjects discussed are:

• Disconnecting devices, short-circuit and overload protection to IEC 60364 (corresponding to DIN VDE 0100) and IEC 60204 (corresponding to DIN VDE 0113)

• Load current supplies and load circuits

• Supply voltages of the ET 200AL distributed I/O system

Grounded infeed

In grounded incoming supplies, the neutral conductor of the supply system is grounded. A simple ground fault between a live conductor and ground or a grounded section of the plant causes the protective devices to trip.

Supply voltages

Provide the ET 200AL distributed I/O devices with a SELV/PELV supply voltage for 1L+.

The supplied SELV/PELV load voltage for 2L+ can be switched, depending on the application.

• 1L+: Supply voltage (non-switched)

• 2L+: Load voltage (switched)

Safe electrical separation (SELV/PELV)

Mains devices/power supply modules with secure electrical separation SELV/PELV are required for the operation of the ET 200AL distributed I/O system. These power supplies/power supply modules must comply with IEC 61010-2-201.

The wiring of SELV/PELV circuits must be separated from the wiring of non-SELV/PELV circuits.

Alternatively, the insulation of all conductors must be dimensioned for the higher voltage.

NOTICE

Operation in damp/wet environments

When operating in a damp/wet environment, other voltage limits apply for SELV/PELV according to IEC 61010-2-201.

Configuring ET 200AL with grounded reference potential

When configuring the ET 200AL distributed I/O system with grounded reference potential, occurring interference currents are discharged into functional earth. The connections must be externally connected (connection between 1M and FE).

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Configuring ET 200AL with ungrounded reference potential

When configuring the ET 200AL distributed I/O system with non-grounded reference potential, occurring interference currents are discharged via an internal RC network to functional earth (no external connection between 1M and FE).

ET 200AL in the overall configuration

The figure below shows the ET 200AL distributed I/O system in the complete electrical configuration using the example of an interface module.

① Main switch

② Short-circuit and overvoltage protection

③ Fuses for cable protection (automatic circuit breaker for 4 A)

④ When configuring the ET 200AL distributed I/O system with non-grounded reference potential, no connection is made between 1M, 2M and FE.

Figure 5-1 Electrical configuration

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Components and protective measures

Various components and protective measures are stipulated for setting up a complete plant.

The types of components and the degree to which the protective measures are mandatory depend on the IEC regulation that applies to your plant setup.

The following table shows the components of the electrical configuration with reference to the previous figure and compares the IEC regulations.

Table 5- 1 Components of electrical configuration Reference to

illustration IEC 60364

(DIN VDE 0100) IEC 60204 (DIN VDE 0113) Disconnection ele-

ment for controller, sensors, and actuators

① Main switch Disconnector

Short-circuit / over-

load protection ② Single-pole protection of circuits

Secure all incoming supply cables with a circuit breaker (24 V DC/4 A).

Secure with one pole with a grounded secondary circuit

Cable protection ③ Protection of cables and wires against overcurrent -

Insulation monitoring

In the following situations, you must provide insulation monitoring.

• When configuring the ET 200AL distributed I/O system with non-grounded reference potential

• When hazardous system conditions may occur due to errors

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5.4 Electrical configuration of the ET 200AL

5.4 Electrical configuration of the ET 200AL

Electrical isolation

When electrically configuring the ET 200AL distributed I/O system, there is electrical isolation between:

• Load voltage 2L+ and all other switching parts

• Communication interfaces (PROFINET/PROFIBUS) of the interface modules and all other switching parts

• ET-Connection and all other switching parts

The following images show the potential conditions of the modules of the ET 200AL distributed I/O system.

Figure 5-2 Potential conditions of the ET 200AL distributed I/O system (Part 1)

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Connection of a digital output with a digital input

NOTICE

Pay attention to the potential group

When a digital output is connected to a digital input, pay attention to the potential groups.

Depending on the configuration, 1M and 2M may then be connected, resulting in elimination of the electrical isolation between 1L+ and 2L+. The possible compensating currents can destroy the digital module.

WARNING

Note potential groups for safety-related shutdown

When a digital output is connected to a digital input, pay attention to the potential groups.

Depending on the configuration, 1M and 2M can then be connected, which leads to elimination of the electrical isolation between 1L+ and 2L+.

The safety-related shutdown is not permitted if the electrical isolation is eliminated.

Cable protection

According to IEC 60364, cable protection is required, i.e. you must always secure the incoming lines externally.

You must secure all incoming supply voltages with a UL/IEC approved 24 V DC/4 A fuse (trigger characteristic type B or C).

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Power supply of the configuration

Two voltage groups are available for the distributed I/O system ET 200AL: 1L+ (supply voltage) and 2L+ (load voltage)

A second infeed may be needed to supply all the modules of a configuration with the required voltage. Renewed voltage supply of 1L+ and 2L+ can be necessary to configure different potential groups or because the voltage is not sufficient for all modules due to the voltage drop. Create a power balance for the selection of the infeed point of the voltage.

Note

Turning 1L+ and 2L+ on and off

In contrast to the load voltage 2L+, the operational switching on and off of the supply voltage 1L+ results in a restart of the module.

The figure below shows a configuration with a new voltage infeed for the modules. The different potential groups have a gray background.

Figure 5-5 Wiring of the power supply

Reference

You will find additional information on electrical configuration and the voltage drop in the section Connecting cables for ET 200AL (Page 50).

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5.5 Connecting ET 200AL to functional earth

5.5 Connecting ET 200AL to functional earth

Introduction

You must connect the distributed I/O system ET 200AL to functional earth (FE)

What is functional earth?

All ET 200AL modules feature a functional earth connection. This connection is used to suppress interference sensitivity, but not for protection purposes. With the functional earth connection, you create an electrical connection directly to a point of your system or shielding.

This discharges the EMC interference directly into the earth. By discharging the EMC interference, the interference safety of the entire module is increased.

The figure below shows the symbol with which the functional earth connection is identified on the ET 200AL modules.

Figure 5-6 Functional earth

5.5.1 Mounting ET 200AL modules on conductive substrate

Requirement

Conductive substrate for mounting of the module

Required tools

To connect to functional earth, you need the following tools:

• Screwdriver

Required accessories:

To connect to functional earth, you need the following accessories:

• 2 x M4 fastening screws.

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Mounting

To connect modules of the ET 200AL distributed I/O system to functional earth with a conductive mounting substrate, proceed as follows:

1. Drill two fastening holes.

2. Screw the module with the M4 fastening screws using a torque of 1.2 Nm.

Note

Earthing with conductive mounting substrate

When you fasten a module of the ET 200AL distributed I/O system on a conductive, grounded substrate, the bottom fastening screw provides a conductive connection to the ground potential.

Ensure that there is a low-impedance connection between the module and conductive underground as well as between the conductive underground and functional earth.

Reference

You will find more information on installing the modules in the section Mounting modules (Page 27).

5.5.2 Mounting ET 200AL modules on non-conductive substrate

Requirement

Conductive substrate for mounting of the module

Required tools

To connect to functional earth, you need the following tools:

• Screwdriver

• Stripping tool

• Crimp tool

Required accessories:

To connect to functional earth on a non-conductive fastening substrate, you need the following accessories:

• 2 x M4 fastening screws.

• Cable lug suitable for M4 screws

• Grounding cable (braided copper cable) with a minimum cross section of 4 mm²

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Mounting

To connect modules of the ET 200AL distributed I/O system to functional earth, proceed as follows:

1. Drill two fastening holes.

2. Strip the grounding cable.

3. Fasten the cable lug to the grounding cable.

4. Screw the module and the cable lug with the M4 fastening screws using a torque of 1.2 Nm.

The figure below shows how to connect functional earth using the example of the IM 157- 1 PN interface module.

Figure 5-7 Connecting the functional earth

Note

Earthing with non-conductive mounting substrate

Make sure there is a low-impedance connection between the module and the functional earth.

Reference

You will find more information on installing the modules in the section Mounting modules (Page 27).

SIMATIC. ET 200AL Distributed I/O system. Preface. ET 200AL Documentation Guide 1. System overview 2. Application planning 3. Mounting 4.

SIMATIC ET 200AL

Distributed I/O system

System Manual

Preface

ET 200AL Documentation

Guide 1

System overview 2

Application planning 3

Mounting 4

Connecting 5

Configuring 6

Configuration control

(option handling) 7

Commissioning 8

Maintenance 9

Technical specifications 10

Safety-related shutdown of

ET200AL standard modules A

Dimension drawings B

Accessories/spare parts C

Legal information

Preface

Purpose of the documentation

Changes compared to previous version

Basic knowledge required

Validity of the documentation

Conventions

Special information

Recycling and disposal

Additional support

Security information

Siemens Industry Online Support

Industry Mall

See also

Table of contents

ET 200AL Documentation Guide 1

Manual Collection ET 200AL

"mySupport"

"mySupport" - Documentation

"mySupport" - CAx data

Application examples

TIA Selection Tool

SIMATIC Automation Tool

PRONETA

SINETPLAN

System overview 2

2.1 What is the SIMATIC ET 200AL distributed I/O system?

SIMATIC ET 200AL

Customer benefits of the system

Area of application

Setup

Configuration example

2.2 What are fail-safe automation systems and fail-safe modules?

Fail-safe automation systems

Safety Integrated

Fail-safe modules

Possible uses of ET 200AL with fail-safe modules

Use in SIMATIC Safety F-systems

Achievable safety classes

2.3 Components

Components of the ET 200AL distributed I/O system

Application planning 3

3.1 Hardware configuration

Mechanical maximum configuration

Electrical maximum configuration

Reference

3.2 Configuration variants with ET-Connection

3.2.1 ET 200AL with ET-Connection

ET-Connection1

ET-Connection1 and ET-Connection2

3.2.2 Hybrid configuration ET 200AL/ET 200SP with ET-Connection

Hybrid configuration ET 200AL and ET 200SP

Requirement

Rules

Rules

Procedure

Mounting 4

4.1 Basics

Introduction